A 2008 Build-Up Thread - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 84 Old 08-01-2012, 08:49 AM Thread Starter
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A 2008 Build-Up Thread

**Mods, if this needs to be moved anywhere more appropriate, please feel free ok! **

Hi everyone! I thought I'd share a build-up of my 2008 model which I took delivery of the other day. There's quite an extensive list of things which will be done to this bike over the coming months, so I hope you all enjoy watching the progress happen. Of course, all comments and suggestions are most welcomed!

I'll start with the condition of the bike as it was at time of taking ownership of it. It had covered a fraction over 23k klm's by one owner, had never been off road, and never been dropped. It was used as a commuter bike along the freeway, hadn't had a hard life, and was clearly very well looked after. A new set of Dunlop 606's were fitted, as well front and rear sprockets and a new battery just prior to the sale., and apart from that it was stock standard.

Now for some pics after a morning of cleaning and detailing it, using a full complement of Meguires products.







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Last edited by KLR Kaos; 08-02-2012 at 11:24 AM.
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post #2 of 84 Old 08-01-2012, 08:52 AM Thread Starter
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And some more...





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post #3 of 84 Old 08-01-2012, 09:22 AM Thread Starter
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Those with a keen eye will have noticed on the dashboard pic a GPS unit fitted below the handle-bars, which for the time being is a temporary location until I give more thought to a better spot. It's a Navman Ezy15...not a particularly flashy unit I know, but it tells me where I'll be going and also what the time iswhen riding, hehe! It's mounted via a RAM bar-mount



I have also fitted an iJet controller mounted on the base of the left hand mirror. This is a wireless and waterproof ipod/iphone controller, and something which I just love!! The location just seemed to be ideal for this. I've also bought a pair of in-helmet headphones, and am going to fit these to my new helmet when I pick it up in a few weeks time.





I'm currently waiting on a lot parts to arrive in the post, so will have to see what shows up for the next installment!
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post #4 of 84 Old 08-01-2012, 04:20 PM
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how exciting! I have subscribed to your thread im very interested in seeing what is to come!
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post #5 of 84 Old 08-01-2012, 11:39 PM Thread Starter
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Quote:
Originally Posted by tantheman4 View Post
how exciting! I have subscribed to your thread im very interested in seeing what is to come!
Thanks mate! There's a LOT of sweet parts and accessories en-route from all corners of the world atm, and my patience is at the mercy of the postal services this week, arghh!! I'm itching to make a real start on the build-up...not just fit a couple of little gizmos which I had on my last bike, hehe!

Put it this way, this will definitely be a build-up to keep an eye on.
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post #6 of 84 Old 08-02-2012, 12:00 AM Thread Starter
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Well it looks like a quiet day for parts arriving...the only thing which just arrived in the post was a sticker for the rear fender to display my UHF channel. Unfortunately it came in black, not the white which I had requested. D'oh! I'm going to send a message to the guy and get him to send another one...but seeing as he's going to have to remake it, have decided to go with silver to match the bike (and it's still highly visable). This is one of those stuff-ups which has worked out ok, lol

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post #7 of 84 Old 08-02-2012, 08:42 AM Thread Starter
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Alrighty...some of you may be aware of what parts I'm currently waiting on, but for the others benefit, below is a list. It's a solid start for now (and while the wallet recovers especially after just getting the bike), hehe! There's a lot more to come very soon though!

- Happy Trails nerf bars
- Happy Trails engine guard
- Happy Trails sump guard
- Happy Trails rallye windscreen system
- Barkbuster handguards
- Oxford hot grips
- Heated seat pad
- Moose Racing seat cover
- Garmin 62S cradle
- Garmin 62S wiring kit
- Mini USB wiring kit
- 12v socket wiring kit
- Flat mount RAM ball (for my Navman road GPS)
- UHF channel sticker for rear fender
- Moose Racing route sheet holder (this should be a hint of the direction this build is going, hehehe!)

Last edited by KLR Kaos; 08-02-2012 at 11:04 AM.
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post #8 of 84 Old 08-02-2012, 11:15 AM Thread Starter
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Next on the list are the following items:
- Braided brake lines
- SBS brake pads
- Stompgrips for the tank
- Subframe upgrade kit
- Oxford digital clock/thermometer
- Fuse block & relays
- Zero Gravity double bubble screen (clear)
- Happy Trails fork brace
- Happy Trails rear master cylinder bracket
- Happy Trails rear master cylinder guard
- Happy Trails centre stand
- Touratech headlight mesh guard

Still weighing up:
- Luggage (still deliberating between Wolfman and Kriega)
- Rotopax fuel cans and carrier system
- Pivot footpegs
- Handlebar risers
- Front fork springs
- Rear shock
- Matching gear shifter and rear brake levers
- Spot lights
- ShuRoo or other wildlife deterrent
- LED brake light and indicators (to help save the power)
- Toolkit (still figuring out exactly what I need)
- Spare parts and inner tubes

I intend to do as thorough a write-up regarding the installations (yes with lots of photos), impressions of the products, delivery times (for the benefit of fellow Aussies), and what impact they have on the bike/riding/functionality.
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post #9 of 84 Old 08-07-2012, 08:23 AM Thread Starter
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I've been away for a few days with work, but today I got a very enthusiastic SMS from my housemate saying that a heap of items had arrived in the post...well he wasn't kidding!!! I'm just gutted to have another 3 days of work so far away from home before I can finally get cracking fitting all this stuff!!!

*this is just a pic of the major items, not the misc fittings, etc*


I'm absolutely flawed at how quick Happy Trails posted to Australia...1.5weeks delivery, huge boxes, and was a painless exercise! The welding, finish, and design of the goodies which I bought from them is most impressive. They really took a lot of effort to ensure the parts were well protected for transit too, and their communication was brilliant too, which I was also impressed by. Double-thumbs up to them!!

Here's the HT sump-guard:


The HT engine guard (I'll be removing the "highway pegs" and their mounting tabs as they're a bit of a wank for my purposes tbh):


The HT tank/radiator/fairing guards:

Last edited by KLR Kaos; 08-07-2012 at 08:43 AM.
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post #10 of 84 Old 08-07-2012, 08:29 AM Thread Starter
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The Barkbusters (purchased in Australia and all proceeds go to charity) 1 week delivery


The HT rallye screen kit:


The wiring kit for the Garmin 62S GPS: (2 week delivery from the US)


The cradle for the Garmin 62S GPS (2 week delivery from the US):


The marine-grade 12v power socket: (2 week delivery from the US)

Last edited by KLR Kaos; 08-07-2012 at 08:46 AM.
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